Joint seal system having internal barrier and external wings

ABSTRACT

An integral multilayer joint seal. Layers of foam, layered co-planar to the adjacent surface, are interspersed with a barrier layer which extends beyond the foam layers to provide a protective surface, a surface for attachment atop adjacent substrates, or a connecting tab for use with adjacent joint seals. The foam layers may be uncompressed or partially compressed at the time of joint formation and may be composed of open or closed, or hybrid, cell foam. The foam may be impregnated with a fire retardant or lay be composed of a fire retardant material, if desired. The barrier may have a tensile strength greater than the adjacent foam. The joint seal may have an elastomer, such as silicone, at its top and/or bottom, and may even include an elastomer layer within or about the barrier.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/189,671 for Joint seal system, filed Jun. 22, 2016, which isa continuation of U.S. patent application Ser. No. 14/630,125, Jointseal system filed Feb. 24, 2015, issued as U.S. Pat. No. 9,404,581 onAug. 2, 2015 which is incorporated herein by reference, and claims thepriority of U.S. Provisional Patent Application No. 61/946,311, filedFeb. 28, 2014 for “Joint Seal System,” which is incorporated herein byreference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND

Field

The present disclosure relates generally to systems for creating adurable seal between adjacent panels, including those which may besubject to temperature expansion and contraction or mechanical shear.More particularly, the present disclosure is directed to providing anintegral multilayer joint seal system against one or more of water,fire, sound, air, smell, radiation, resistant and/or heat.

Description of the Related Art

Construction panels come in many different sizes and shapes and may beused for various purposes, including roadways, sideways, and pre-caststructures, particularly buildings. Use of precast concrete panels forinterior and exterior walls, ceilings and floors, for example, hasbecome more prevalent. As precast panels are often aligned in generallyabutting relationship, forming a lateral gap or joint between adjacentpanels to allow for independent movement, such in response to ambienttemperature variations within standard operating ranges, buildingsettling or shrinkage and seismic activity. Moreover, these joints aresubject to damage over time. Most damage is from vandalism, wear, andenvironmental factors, where the seal may become thick and inflexible orare fragile. As a result, “long lasting” in the industry refers to ajoint likely to be usable for a period greater than the typical lifespanof five (5) years. Various seals have been created in the field.

Various seal systems and configurations have been developed forimposition between these panels to provide seals which provide one ormore of fire protection, waterproofing, and air insulation. Thistypically is accomplished with a seal created by imposition of multipleconstituents in the joint, such as silicone application, backer bars,and compressible foams. Alternative prior art systems have includedextruded glands and metallized bellows.

These systems, however, often fail due to the differences in compressionand expansion of the various constituents, or the lack of bondingbetween layers, or because the system is directed to a particularpurpose, such as water-resistance, but is exposed to fire, causing theseal system to fail and permit water to migrate behind the seal system.Vandalism, normal wear, and environmental exposure can change or defeatthe properties of the exposed surface coating or membrane. There is alsothe case where the best material or barrier may not be used because itis aesthetically unpleasing or cannot easily be colored. By moving themembrane feature to an internal level sufficient to protect it and allowfor the best properties of the joint sealant, these limitations can beovercome and the useful lifespan extended.

Additionally, in some cases the movement of the joint may be limited,sometimes to only twenty-five percent (+/−25%) in compression andexpansion, for a total movement of only fifty percent (50%). Thesesystems often use closed-cell, rather than open-cell, polyurethanefoams. The need exists for a seismic joint having at least about fiftypercent (50%) movement in each direction, for a movement total of aboutone hundred percent (100%) or more.

It would be an improvement to the art to provide a joint seal systemwhich would include a plurality of compressible layers joined into asingle unit prior to imposition and which would include a membranebarrier positioned intermediate two compressible layers. It would be afurther improvement to provide the various compressible layers withdiffering functional properties, such as, for example, waterproofingand/or fire retardancy and durability associated with fire ratings.

Additionally, for pre-compressed joint sealants with a silicone face, amyriad of potential failure risks exists. Typically, the surface coatingof these joints is relatively thin and can be damaged. Where jointsubstrate is irregular, a complete seal at the joint face might not beaccomplished. Water intrusion from behind the joint face could find itsway into or past the joint sealant and may result in poor performance ora leak, particularly problematic is products that rely on water-basedintumescent surface coating, which can revert or delaminate if subjectto continuous moisture. Pre-compressed or compressible joint sealantswithout an elastomer coating or surface impregnation often have similarlimitations.

It would therefore be are improvement to safeguard the criticalfunctions, by way of membrane barrier or the membrane barrier separatingdifferent operations of the foam, away from the surface where they canbe damaged or bypassed. Thus, the joint seal surface will serve itsprimary aesthetic function of filling the joint with a matching orpleasing color without having the primary purpose of the system (water,fire etc.) subject to failure from superficial damage.

Additionally, foam sealants can take a compression set at some point. Ifthe foam sealant systems designed based on laminations (acrylics orstrong pressure sensitive adhesives in particular) are parallel to thejoint substrate, they tend to separate over time, losing their sealantproperties. The norm for these pressure sensitive adhesives impregnatedsystems is to use multiple, parallel laminations that are held togetherby their own adhesive force. These types of systems rely heavily on theelastomer surface coating for sealing and intumescent surface coatingsfor fire resistance. If there is any damage to the thin (60 mil or lesscoating) the system will not perform as designed. This is furthercomplicated by the use of the multiple laminations that if separatedwould let water, smoke or fire penetrate system. Failure of any of theselisted shortcomings will reduce the useful lifespan of the jointsealant.

Because the primary sealant is always subject to adhesive, cohesive, andenvironmental forces and therefore tends to wear out over time and leak,it is a good practice to have redundant systems.

Therefore, it would be an improvement to provide a joint seal with itsown redundancy, particularly with regard to compression of foam seals.

Finally, it would be an improvement to provide a joint seal having alaminated or profiled lamination structure that could benefit from thepush pull function of the joint.

SUMMARY

The present disclosure therefore meets the above needs and overcomes oneor more deficiencies in the prior art by providing a joint seal systemwhich provides a plurality of compressible layers, which may havedifferent functional properties, joined into a single unit prior toimposition and which includes a barrier intermediate the plurality ofcompressible layers.

The joint seal therefore includes a first body of compressible foam, asecond body of compressible foam, and a barrier adhered to both thefirst body of compressible foam and the second body of compressiblefoam, wherein all three components preferably have equivalent lengthsand are aligned to provide common ends.

The joint seal is constructed by providing a first body of compressiblefoam, providing a second body of compressible foam, providing a barrier,adhering the barrier to the first body of compressible foam at the firstbody bottom, and cutting the first body of compressible foam, the secondbody of compressible foam, and the barrier to provide a common firstend, and a common second end.

In an alternative embodiment, the joint seal includes a first body ofcompressible foam, a second body of compressible foam, and a barrieradhered to both the first body of compressible foam and the second bodyof compressible foam, wherein the foam bodies have equivalent lengthsand widths but the barrier extends beyond the edge of the first body ofcompressible foam on at least one side, which may turned up or down andadhered to the foam or the substrate, or which may be driven intoadjacent joint systems or may be overlaid adjacent substrates beforebeing covered with substrate materials or other covering.

The present invention thus provides redundancy, and potentially a statusnotification of change in critical joint conditions in situ forwater-resistant, fire-resistant and/or roof expansion joints.

Additional aspects, advantages, and embodiments of the disclosure becomeapparent to those skilled in the art from the following description ofthe various embodiments and related drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the described features, advantages, andobjects of the disclosure, as well as others which will become apparent,are attained and can be understood in detail; more particulardescription of the disclosure briefly summarized above may be had byreferring to the embodiments thereof that are illustrated in thedrawings, which drawings form a part of this specification. It is to benoted, however, that the appended drawings illustrate only typicalpreferred embodiments of the disclosure and are therefore not to beconsidered limiting of its scope as the disclosure may admit to otherequally effective embodiments.

In the drawings:

FIG. 1 is an illustration of an end view of the expansion joint sealsystem of the present disclosure.

FIG. 2 is an illustration of a view of the expansion joint seal systemof the present disclosure.

FIG. 3 is an illustration of a view of an alternative expansion jointseal system of the present disclosure.

FIG. 4 is an illustration of a further alternative expansion joint sealsystem of the present disclosure.

FIG. 5 is an illustration of a further alternative expansion joint sealsystem of the present disclosure.

FIG. 6 is an illustration of a further alternative expansion joint sealsystem of the present disclosure.

FIG. 7 is an illustration of a further alternative expansion joint sealsystem of the present disclosure.

FIG. 8 is an illustration of the further alternative expansion jointseal as installed into a substrate.

FIG. 9 is an illustration of an alternative expansion joint seal systemof the present disclosure.

FIG. 10 is an illustration of a side view of one embodiment of theexpansion joint seal system of the present disclosure.

FIG. 11 is an illustration of a further alternative expansion joint sealsystem of the present disclosure.

FIG. 12 is an illustration of a further alternative expansion, jointseal system of the present disclosure.

FIG. 13 is an illustration of a further alternative expansion joint sealsystem of the present disclosure.

FIG. 14A is an illustration of the present disclosure when used in thetransition from a horizontal to vertical joint wherein the first body ofcompressible foam and the second body of compressible foam include aright angle turn.

FIG. 14B is an illustration of the present disclosure when used in thetransition from a horizontal to vertical joint wherein a section of oneof the first body of compressible foam and the second body ofcompressible foam is joined or attached to another section in rightangle abutment and the associated one of the second body of compressiblefoam and the first body of compressible foam is joined or attached tothe other section in a mitered cut.

FIG. 14C is an illustration of the present disclosure when used in thetransition from a horizontal to vertical joint wherein the first body ofcompressible foam and the second body of compressible foam of onesection is joined or attached to another section in a mitered cut.

FIG. 14D is an illustration of the present disclosure when used in thetransition from a horizontal to vertical joint wherein a section of oneof the first body of compressible foam and the second body ofcompressible foam is joined or attached to another section in rightangle abutment and the associated one of the second body of compressiblefoam and the first body of compressible foam is joined or attached tothe other section in a offset right angle abutment, such that the endsof the first body of compressible foam and the second body ofcompressible foam are not co-terminus.

FIG. 14E is an illustration of the present disclosure when used in thetransition from a horizontal to vertical joint wherein a section of oneof the first body of compressible foam and the second body ofcompressible foam, which includes a right angle extension occurringbeyond the first end of one body and terminating in a mitered cut, isjoined or attached to another section in right angle abutment, butwherein the one of the first body of compressible foam and the secondbody of compressible foam terminates in a mitered cut.

FIG. 14F is an illustration of the present disclosure when used in thetransition from a horizontal to vertical joint wherein one of the firstbody of compressible foam and the second body of compressible foamterminates in a mitered cut.

FIG. 15 is an illustration of an alternative embodiment of the presentdisclosure.

FIG. 16 is an illustration of an alternative embodiment of the presentdisclosure.

FIG. 17 is an illustration of an alternative embodiment of the presentdisclosure.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a joint seal 100 is provided for impositionunder compression between a first substrate 102 and a second substrate104 separated by a distance 105. The joint seal 100 includes a firstlateral body of compressible foam 120, a second lateral body ofcompressible foam, and a lateral barrier 134, which are joined togetherto form an integral unit prior to the imposition under compressionbetween the first substrate 102 and the second substrate 104. Theformation of the joint seal 100 as an integral unit prevents the failuretypically seal at such joints where a component of the joint system hasseparated from the joint and partly, or entirely, migrated out of thejoint between the two substrates. The joint seal 100 of the presentdisclosure thus allows for sealing between substrates, such as roofjoint substrates, at depths greater than typical, such as up to 6 inchesdeep, which may allow for functional features and addresses a knownpoint of failure. Beneficially, the present disclosure allows for use ofthe joint seal 100 on roof-top patios or plazas as the joint seal 100does not use a convex bellows design, but instead may rest nearly flushwith the roof line. As can be appreciated, in such situations, andotherwise, the joint seal 100 may be provided in a variety of colorsknown in the art, including typical black and white, but also includingcolors which match the surrounding, such as green. To facilitate thispurpose, the foam may be open or closed cell, or may be elected from anyother material have similar compressibility and durability.

Consistent with this purpose, the first body of compressible foam 120 issized for use in the joint seal system, specifically to extend laterallyfrom a first substrate 102 to a second substrate 104, and therefore hasa first body top 118, a first body bottom 122, a first body length 202,a first body first end 204, a first body width 124, a first body firstside 206, and a first body second side 207. The first body ofcompressible foam 120 may be an open-celled foam, a closed-celled foam,or a hybrid foam. Depending on the selection of foam, the first body ofcompressible foam 120 may therefore have a predetermined waterresistance. The first body of compressible foam 120 may be impregnatedwith a fire retardant, such as in a liquid medium, if at all, or may becomposed of a fire-retardant material, if desired, and thereby have somedegree of fire retardancy. The first body of compressible foam 120 maytherefore be a fire retardant closed cell foam. Thus the first body ofcompressible foam 120 has a first body fire retardancy. The first bodywidth 124 is sized to the distance 105 between the first substrate 102and the second substrate 104 so as to contact the first substrate 102 atthe body first side 206.

Similarly, the second body of compressible foam 128 is sized forformation of an integral unit with the first body of compressible foam120 and to extend laterally from a first substrate 102 to a secondsubstrate 104. The second body of compressible foam therefore has asecond body top 126, a second body bottom 130, and a second body length208, a second body first end 210, a second body width 132, and a secondbody first side 212. The second body of compressible foam 128 may be anopen-celled foam, a closed-celled foam, or a hybrid foam. Depending onthe selection of foam, the second body of compressible foam 128 maytherefore have a predetermined water resistance, which may be greaterthan, equal to or less than the water resistance of the first body ofcompressible foam 120. The second body of compressible foam 128 may beimpregnated with a fire retardant, if at all, or may be composed of afire-retardant material, if desired, and thereby have some degree offire retardancy. The second body of compressible foam 128 may thereforebe a fire retardant closed cell foam. Similarly, the second body ofcompressible foam 128 has a second body fire retardancy, which may beequal to, less than, or greater than the first body fire retardancy.

The second body width 132 is sized, under the desired compression, tothe distance 105 between the first substrate 102 and the secondsubstrate 104.

While the first body of compressible foam 120 has a first body firerating, and the second body of compressible foam 128 has a second bodyfire rating, the first body fire rating need not be the same as thesecond body fire rating. Moreover, while this first body of compressiblefoam 120 provides a primary sealant layer, it can be altered as a resultof any water which permeates into it, as this changes is properties,thus fire-rating properties may differ in case of water penetration, acircumstance which must be accounted for in any testing regime.Fortunately, because the second body of compressible foam 128 isprotected from water penetration by the barrier 134, the functionalproperties, such as the fire-rating properties, of the second body ofcompressible foam 128 are not compromised. Similarly, the second body ofcompressible foam 128 may be protected from deleterious materials, suchas flowing chemicals, by the barrier 134. A body's fire rating mayinclude the temperature at which the body burns, or flame spreads, or,in conjunction with or as an alternative thereto, the time-duration atwhich a body passes any one of several test standards known in the art.In one embodiment, the first body fire rating is unequal to the secondbody fire rating. Selection of the fire rating for the various layers ofthe joint seal 100 may be made to address operational issues, such as ahigh fire rating for the first layer or body 120, which will be directlyexposed to fire, but which may provide limited waterproofing, coupledwith a second body of compressible foam 128 which may have a lower firerating, but a higher waterproofing rating, to address the potential lossof the first body of compressible foam 120 in a fire. The first body ofcompressible foam 120 may be fire resistant but may ablate in responseto exposure, shedding size or volume when exposed to high temperature orfire with the membrane separating it from other layers, which may retaintheir structural integrity or otherwise continue to provide some sealingfunction and providing functional properties during exposure. Theselection of foam, fire retardant impregnation, thickness andcompression after imposition may provide sufficient resilience torepeated compression to pass at least one of the cycling regimes forvarious fire rating regimes, such as Underwriters Laboratories 2079, andmay likewise provide sufficient fire retardancy to rate at least aone-hour rating, but preferably more, based on the Cellulosictime/temperature curve, such as UL 2079, ISO 834, BS 476: part 20, DIN4102, etc. The Cellulosic time-temperature curve is described by theknown equation T=20+345*LOG(8*t±1) where t is time, in minutes, and T istemperature in degrees Celsius.

Detection of a compromised primary seal, the first body of compressiblefoam 120, may be addressed by the inclusion in the joint seal of radiofrequency identification devices (RFIDs), which are known in the art,and which may provide identification of circumstances such as moisturepenetration and accumulation. The inclusion of an RFID in the joint seal100 may be particularly advantageous in circumstances where the jointseal 100 is concealed after installation, particularly as moisturesources and penetration may not be visually detected. Thus, by includinga low cost, moisture-activated or sensitive RFID above or atop thebarrier 134, the user can scan the joint seal 100 for any points ofweakness due to water penetration. The barrier 134 may include a heatsensitive RFID, thus permitting identification of actual internaltemperature, or identification of temperature conditions requiringattention, such as increased temperature due to the presence of fire,external to the joint or even behind it, such as within a wall. Suchdata may be particularly beneficial in roof and below gradeinstallations where water penetration is to be detected as soon aspossible.

Inclusion of RFIDs may provide substantial benefit for informationfeedback and potentially activating alarms or other functions within thejoint sealant or external system. Fires that start in curtain walls arecatastrophic. High and low pressure changes have deleterious effects onthe long-term structure and the connecting features. Providing real timefeedback from sensors, particularly given the inexpensive cost of suchsensors, in those areas and particularly where the wind, rain andpressure will have their greatest impact would provide benefit. Whilethe pressure on the wall is difficult to measure, for example, thedeflection in a pre-compressed sealant is quite rapid and linear.Additionally, joint seals are used in interior structures including butnot limited to bio-safety and cleanrooms. When used, the temperaturesensing function of the barrier 134 may be extended by use of aheat-conductive material in or on the barrier 134, such that the barrier134 is heat conductive, in communication with the RFID. Additionally, anRFID may be in connection or communication with anelectrically-conductive barrier 134, such that a break in the barrier134 may be immediately detected as a result of a change in conductivity.This may be accomplished by a copper membrane, a scrim, or mesh. AFaraday cage or shield may therefore also be used to limit electricalinterference. Additionally, an RFID could be selected which wouldprovide details pertinent to the state of the Leadership in Energy andEnvironmental Design (LEED) efficiency of the building. Additionally,such an RFID, which could identify and transmit air pressuredifferential data, could be used in connection with masonry wall designsthat have cavity walls or in the curtain wall application, where the airpressure differential inside the cavity wall or behind the cavity wallis critical to maintaining the function of the system. RFIDs may bepositioned in other locations within the joint seal 100 to providebeneficial data. An RFID may be positioned within first body ofcompressible foam 120 at or near the first body top 118 to provideprompt notice of detection of heat outside typical operating parameters,so as to indicate potential fire or safety issues. Such a positioningwould be advantageous in horizontal of confined areas. An RFIDpositioned within first body of compressible foam 120 at or near thefirst body top 118 might alternatively be selected to provide moisturepenetration data, beneficial in cases of failure or conditions beyonddesign parameters. The RFID may provide data on moisture content, heator temperature, moisture penetration, and manufacturing details, and maybe in contact with the first body of compressible foam 120, the secondbody of compressible foam 128, the third body of compressible foam 302,and/or the second resilient flexible barrier 304. In such cases, theRFID provides notice of exposure from the surface of the joint seal 100most distant from the base of the joint. Alternatively, or in addition,an RFID can be positioned at or near the second body bottom 130 of thesecond body of compressible foam 128 to provide the same data (fire orwater penetration) from the side most distant to the surface sealed.Further, RFIDs could be positioned at or near each end 204 of the firstbody of compressible foam 120 and/or the second body of compressiblefoam 128 so as to communicate relative position to the RFID positionedin the adjacent joint seal 100, such as where butt ends are splicedtogether, so as to identify any separation, or misalignment, of adjacentjoint seals 100. Similarly, an RFID may be selected which providesnotice of RF loss.

RFIDs may further provide real time data. Using moisture sensitiveRFID's in the joint seal 100 and at critical junctions/connection wouldallow for active feedback on the waterproofing performance of the seal100. It can also allow for routine verification of the watertightness ofa roof joint with a hand-held RFID reader to find leaks before the reachoccupied space and to find the source of a sting leak. Often waterappears in a location much different than it originates making itdifficult to isolate the area causing the leak. A positive reading fromthe RFID alerts the property owner to the enact location(s) that havewater penetration without or before destructive means of finding thesource. The use of an RFID in the joint seal 100 is not limited toidentifying water intrusion but also fire, heat loss, air loss, break injoint continuity and other functions that cannot be checked bynon-destructive means.

Use of an RFID within the body may provide a benefit over the prior art.Impregnated foam materials, such as the first body of compressible foam120 and/or the second body of compressible foam 128, are known to curefastest at exposed surfaces, encapsulating moisture remaining inside thebody, and creating difficulties in permitting the removal of moisturefrom within the body. While heating is a known method to addressingthese differences in the natural rate of cooling, it unfortunately maycause degradation of the foam in response. Similarly, while forcing airthrough the foam bodies may be used to address the curing issues, thepotential random cell size and structure impedes airflow and impedespredictable results. Addressing the variation in curing is desirable asvariations affect quality and performance properties. The use of an RFIDwithin the body may permit use of the heating method while minimizingnegative effects. A heat-sensing RFID sensor may be positioned near thesurface (within 10% of the surface) of the first body of compressiblefoam 120 and/or the second body of compressible foam 128 and a moisturesensitive RFID may be positioned in the central ⅓ of the first body ofcompressible foam 120 and/or the second body of compressible foam 128.The data from the RFIDs, such as real time feedback from the heat,moisture and air pressure RFID, aids in production of a consistentproduct. Moisture and heat sensitive RFID s aid in determining and/ormaintaining optimal impregnation densities, airflow properties of thefoam during the curing cycle of the foam impregnation. Placement of theRFID's into foam at the pre-determined different levels allows foroptimum curing allowing for real time changes to temperature, speed andairflow resulting in increase production rates, product quality andtraceability of the input variables to that are used to accommodateenvironmental and raw material changes for each product lots.

With the first body of compressible foam 120 and the second body ofcompressible foam 128, the joint seal 100 includes a barrier 134,positioned intermediate the first body of compressible foam 120 and thesecond body of compressible foam 128 so as to be laterally aligned witheach and to extend laterally from at or near a first substrate 102 to ator near a second substrate 104. So as to be sized with the first body ofcompressible foam 120 and the second body of compressible foam 128, thebarrier 134 has a barrier length 214, a barrier width 136 a barrierfirst end 216, and a barrier first side 218. The relative thickness 123,127, 125 of each body 120, 128 and of a barrier 134 is dependent on thecompositions selected for each layer or body 120, 128, the overallthickness of the joint seal 100, and the operating width of the jointseal 100. In the preferred embodiment, the thickness 123, 127 of thefirst body 120 and the second body 128 do not vary by more than fiftypercent (50%) from one another, and no barrier is less than twenty-fivepercent (25%) of the thickness 123, 127 of the thinnest body 120, 128.The barrier 134 may facilitate installation of the joint seal 100, andmay provide a temporary or permanent bond to the adjacent substrate.Moreover, after installation, the barrier 134 may allow for independentoperation. The barrier 134 is adhered or otherwise bonded to the firstbody of compressible foam 120 and the second body of compressible foam128, which may be accomplished by adhesives or chemical bonding, gluingor melting, or other methods known in the art to cause the barrier 134to retain contact with one or both of the first body of compressiblefoam 120 and the second body of compressible foam 128 in response tomovement. Thus, adhered is not limited solely to the use of adhesivesbut may include other methods known in the art. The barrier 134 may beliquid applied, may be a pre-cured system, or a fabricated element.

The thickness 127 of the second body of compressible foam 128 may betwice the thickness 123 of the first body of compressible foam 120,which has the benefit of moving the barrier 134 closer to the surfacewhere the barrier 134 can better transfer loads, particularly when widerthan the first body of compressible foam 120.

The barrier 134 may include a layer of a heat barrier, an infraredbarrier, a high tensile barrier, a water barrier, air barrier and/or ora vapor barrier. The barrier 134 may include an intumescent material orhave an intumescent material located on one or both sides of the barrier134. In applications requiting the barrier 134 to be a redundant sealthe intumescent is preferably placed opposite the anticipated exposure.It one or both of the first body of compressible foam 120 and secondbody of compressible foam 128 is not fire resistant, the intumescentprovides a protective fire resistant layer. Similarly, if one or both ofthe first body of compressible foam 120 and second body of compressiblefoam 128 is fire resistant, the intumescent would offer additional fireresistance. Incorporating an internal fire resistance into the barrier134 can increase the fire endurance of the joint seal 100, in some casesto greater than 4 hours without increasing the depth of foam required.In cases of wider pre-compressed foam-based expansion joints, thebarrier 134 may be formed of a heavy-duty membrane, having an increasedthickness and durability to provide beneficial support for such widerjoints, particularly horizontal joints up to twelve inches (12″) inwidth. The barrier 134 may be selected based on performancecharacteristics needed. Examples include materials such as hylenepropylene diene monomer rubber, nitrile polyvinyl chloride, polyvinylchloride, thermoplastic vulcanizate, styrene-butadiene-styrene modifiedbitumen, atactic polypropylene modified bitumen, built-up roofmembranes, which integrate well with common roofing systems, which mayinclude membrane or liquid applications, such as asphalt, thermoplasticvulcanizate, polyvinyl chloride, thermal plastic olefin modifiedbitumen, adhering systems, mechanically attached systems. The membrane134 may be also be selected for self-function or performance and may be,for example, heat insulating, heat infrared reflective, ornon-combustible.

The joint seal 100 provides improved durability to a known problem inthe art regarding wide joints, particularly traffic joints, which mustsustain pedestrian and vehicular traffic and the highly-concentratedforces associated with such traffic, such as, for example, small ornarrow heels. A barrier 134 having a thickness of at least 0.03 inches(30 mil) better supports transfer loads such as cart wheels and foottraffic and provides durability comparable to use of a cover plate orassembly of spline and cover plate. The profile cut illustrated in FIG.6, for example, is particularly beneficial in electromagnetic field(EMF) applications. Typically, in such situations, the type of copperfoil associated with the EMF shielding fatigues and fails after a smallnumber of cycles if required to randomly self “accordion” or flex withinthe foam. A barrier 134 of copper foil having a thickness of at least0.1875 inches or a copper scrim ten (10) inches by ten (10) inchesprovides cycling durability equivalent to that experienced over fiveyears of thermal cycling.

The membrane barrier 134 provides a further benefit in secondarycontainment applications where the joint is unattended for long periodbut must perform in an emergency. If the exposed surface is damaged orworn out it will fail. As the internal sealing membrane, barrier 134will be protected and will function. The barrier 134 is sufficient topreclude penetration under intended operating conditions, such that abarrier for a one-hour rated fire-resistant expansion joint provides asufficient barrier to ensure, together with the other components,including the various bodies and any other barriers, that the joint sealpasses the applicable test used to determine the fire-rating. The jointseal 100 further provides a seal potentially capable of sustaininghydrostatic pressure, unlike the prior art. Typically, the density ofthe bodies of compressible foam reaches and ultimately limit where it nolonger performs as a movement joint. In the prior art, a gland by itselfis not sufficient to provide the function as a fail-safe secondarycontainment joint seal but it has been found that by combining it withfoam core seal lamination that head pressures greater that 25′ can beachieved. The high density of the first body 120 and the second body 128required to function as an expansion joint in a high head pressureapplication is however greater than can be achieved while allowing forthe material to act as a movement joint. The joint seal 100 overcomesthis shortcoming by using as the barrier 134 a high-density membrane ina pattern such that it can facilitate compression yet provide theexpansion and movement properties required for the joint seal 100.Because of the barrier 134, and even more beneficial with a connectionto the substrate, the density of the first body 120 or the second body128 can be maximized for support without reaching a density that limitsthe function as a movement joint. Integrated horizontal to verticalfactory manufactured transitions using the same design are not requiredbut allow for a faster transition and connection in critical sealingapplication.

Split-slab and deck applications can be configured such that the barrier134 extends through metal side supports or can used as part of amechanical joint assembly.

Thus, regardless of the circumstance, the joint seal 100 may be used asa standalone system or with dissimilar mechanical connections and commonmetal cover plates as known in the art.

Further, where the barrier 134 is electrically conductive, electricalcurrent may be provided to the barrier 134, which by virtue of itsresistance will cause the barrier 134 to radiate heat, which may besufficient to encourage expansion or field curing of the joint seal 100.This internal heating may be beneficial during installation of a jointseal 100 during cold temperatures, might cause the rate of expansion ofthe joint seal 100 to be slowed. Such internal heating may further bebeneficial to prevent freezing or the accumulation of ice atop the jointseal 100. Internal heating may even be beneficial in warm temperatureinstallations in connection with an impregnation intended to provide aslow release to retain the joint seal 100 in a compressed state untilexpansion is required. The internal heating provided by anelectrically-conductive barrier 134 may further benefit installation ofabutting joint seals 100 as radiated heat may further the bonding ofjoint unions during curing or may be used as a heat accelerating orinducing means for a joint sealant adhesive. Further, anelectrically-conductive barrier 134 may be identification of moisture(water) penetration through the first body of compressible foam 120, assuch moisture would alter the characteristics of the barrier 134,particularly conductance (G measured in siemens or mhos), resistance (Rin ohms) or loss of energy to ground of the joint seal 100 betweensections. Alternative, as illustrated in FIG. 10, anelectrically-conductive thread or mat 1024 may be applied to the barrier134. Similar function could be obtained by the addition a carbonaceouspowder, carbon graphite, copper or other conductive powder or filler tothe first body of compressible foam 120 or impregnation compoundassociated with the first body of compressible foam 120. Conductivefillers have the benefit of yielding variable resistance in the jointseal 100 based on the compression ratio of the foam allowing thepotential for feedback, whether immediate or of limited delay, about theexpansion joint dynamics in critical applications.

By laminating in a coplanar orientation, the foam of the first body 120or the second body 128 is not separated by the normal cyclical movementof the joint occurs with parallel laminations under compression andextension cycling.

In the first embodiments of the joint seal 100, these various dimensionsare generally equivalent, i.e. substantially the same. The first bodylength 202, the barrier length 214 and the second body length 208 aregenerally equivalent, i.e. substantially the same, for provide a commonlength. Similarly, the first body width 124 and the second body width132 are generally equivalent, i.e. substantially the same, for provide acommon width. The barrier width 136 may be equivalent, i.e.substantially the same, to the first body width 124 and the second bodywidth 132.

To form the integral whole, the barrier 134 is adhered to the first bodyof compressible foam 120 at the first body bottom 122, the barrier 134is adhered to the second body of compressible foam 128 at the secondbody top 126. This may be accomplished by use of a conventionaladhesive. The group of the first body first end 204, the second bodyfirst end 210, and the barrier first end 216 are co-planar, and thegroup of the first body first side 206, the second body first side 212,and the barrier first side 218 may be also co-planar.

When installed, the joint seal 100 provides advantages over the priorart. When installed, the joint seal 100 is compressed between the firstsubstrate 102 and the second substrate 104, such that each side of thejoint seal 100 is in contact with an exposed side 112, 116 of the firstsubstrate 102 and the second substrate 104. While the joint seal 100 maybe maintained in place with adhesive on its sides, some water resistanceis provided as a result of the joint seal 100 remaining in somecompression after installation. The joint seal 100 is selected for usewhere at least the first body width 124 is greater, absent any lateralforces on the joint seal 100, than the distance or gap 105 between theexposed side 112 of the first substrate 102 and the exposed side 116 ofthe second substrate 104. The joint seal 100 is laterally compressed andin positioned in the gap between the first substrate 102 and the secondsubstrate, and preferably below, or equivalent, i.e. substantially thesame, with, one or both of the top surface 101 of the first substrate102, a distance 110 above the bottom of the gap 105, and the top surface103 of the second substrate 104, a distance 114 above the bottom of thegap 105. As the first body width 124 is greater than the distance or gap105 between the exposed side 112 of the first substrate 102 and theexposed side 116 of the second substrate 104, the joint seal 100 remainsin compression. The lateral forces attempting to return to the jointseal 100 to the uncompressed, original state, cause the joint seal 100to remain in place and for any adhesive to remain in full contact withthe sides 112, 116 of the substrates 102, 104.

When exposed to fire, the first body of compressible foam 120 may bepartially, or entirely, consumed by fire, but the barrier 134 preventsthe fire from consuming the second body of compressible foam 128, suchthat when fire suppression equipment is used, the first body ofcompressible foam 120 may be blown out of the joint, but the remainingsecond body of compressible foam 128 and barrier 134 prevent water orother materials from entering the joint between the panels, which couldotherwise require removal of the panels.

Thus, the joint seal 100, as a seal for imposition under compressioninto to a joint, may have a first body of compressible foam 120, asecond body of compressible foam 128, and a resilient flexible barrier134. The first body of compressible foam thus has a first body bottom122, a first body thickness 123, a first body first side 206, a firstbody second side 207. The second body 128 thus has a second body top126, a second body first side 212, and a second body second side 211.The resilient flexible barrier 134 thus has a resilient flexible barrierfirst wing 1006 extending beyond the first body first side 206 and thesecond body first side 212, which may be a distance greater than thefirst body thickness 123. The resilient flexible barrier 134 furtherthus has a resilient flexible barrier second wing 1008 extending beyondthe first body second side 207 and the second body second side 211 adistance greater than the first body thickness 123. The resilientflexible barrier 134 further thus has the resilient flexible barrier 134adhered to the first body of compressible foam 120 at the first bodybottom 122 from the first body first side 206 to the first body secondside 207, and the resilient flexible barrier 134 adhered to the secondbody of compressible foam 128 at the second body top 126 from the secondbody first side 212 to the second body second side 211.

Referring to FIG. 1, the, joint seal 100 may further include anelastomer 138, such as silicone, adhered to the first body top 118and/or to the bottom of the bottom-most layer or body 128, the secondbody bottom 130 in the first embodiment. Alternatively, as illustratedin FIG. 9 the joint seal 100 may alternatively include a resilientflexible surface barrier 902, such as one or more layers of a syntheticrubber roofing membrane, including ethylene propylene diene terpolymer(EPDM), bonded or adhered to the first body top 118, such as by heatingof materials or by adhesive. The surface barrier 902 may include at itsdistant end 904 an upper elongate appendage 906 and, below and generallycoplanar, a lower elongate appendage 908, formed, for example, by thelack of adhesive between two adjacent layers or bodies and by cutting asingle layer or body along its edge 910. The surface barrier 902 may lapover or about the membrane of a roofing system to provide an effectiveseal. The surface barrier 902 may be heated or adhesively bonded to theroofing system, or may be affixed with fasteners or anchoring strips tothe roofing system. The surface barrier 902 may include a layer from atleast one of a heat barrier, an infrared barrier, a high tensilebarrier, a water barrier, air barrier and a vapor barrier. Theembodiment depicted in FIG. 9 may therefore provide substantialbenefits, including insulation, sound dampening, water resistance, fireresistance, accommodation of roof expansion and may provide a redundantseal to the internal pre-compressed foam. The surface barrier 902 thusprovides a continuous barrier which may be used as a roof joint sealant,which ties into the building to provide waterproofing, and may be usedto join to vertical joint systems. The resulting continuity of barrierprovided may be particularly beneficial in below grade applications andapplications where a hydrostatic head may be present.

Referring now to FIG. 3, in another embodiment, the joint seal 100 mayfurther include a third body of compressible foam 302 and a resilientflexible second barrier 304. In this embodiment, the third body ofcompressible foam 302 includes a third body top 306, a third body bottom308, a third body length 310, a third body first end 312, a third bodywidth 314, and a third body first side 316. The first body length 202and the third body length 310 are equivalent, i.e. substantially thesame, and the first body width 124 and the third body width 314 areequivalent, i.e. substantially the same. In this embodiment, the secondbarrier 304 is adhered to the second body of compressible foam 128 atthe second body bottom 130 and is adhered to the third body ofcompressible foam 302 at the third body top 306. The second barrier 304would include a layer of a heat barrier, an infrared barrier, a hightensile barrier, a water barrier, air barrier and/or a vapor barrier,which need not be identical to the barrier 134. The first body first end204 and the second barrier first end 315 are co-planar, and the firstbody first side 206 and the second barrier first side 318 may beco-planar.

The relative thickness of the third body of compressible foam 302 and ofthe second barrier 304 is likewise dependent on the compositionsselected for each layer, the overall thickness of the joint seal 100,and the operating width of the joint seal 100. In the preferredembodiment, the thickness of the third body of compressible foam 302does not vary by more than twenty-five percent (25%) from the otherbodies, and the second barrier 304 is less than twenty-five percent(10%) of the thickness of the thinnest body 120, 128, 302. Thisembodiment can therefore provide redundant sealing above and below a tiemembrane, joint connection or building component. This double layer orbody embodiment may be used along the length of one or both substratesand one or both ends of a joint section.

The barrier 134 and the second barrier 304 need not be a solid whenadhered to the respective bodies of compressible foam, but may be aliquid or powder, including or separate from, the adhesive. Moreover,the embodiment of FIG. 3 may be constructed with the equivalently-sizedprofile, i.e. substantially the same, cut for the first body ofcompressible foam 120, the barrier 134, the second barrier 304, thesecond body of compressible foam 128, and the third body of compressiblefoam 302, while the second barrier 304 may utilize the wing 602 andsinusoidal shape depicted in FIG. 6. As a result, a barrier which isbetween 0.1875 and 0.325 inches wide but the same height allows for abarrier thickness of up to 0.06 inches (60 mils). Where a barrier,whether the barrier 134 or a second barrier 304, is formed of rigidcopper, particularly a rigid copper barrier formed in a sinusoidalshape, it is advantageous for each body of compressible foam 120, 128abutting the barrier to formed to the same sinusoidal shape so that thecomponents mesh together. Thus, the second barrier 304 may be set innosing or concrete, or supplied with an adhesive on the ends orunderside of the second barrier 304 to facilitate the installation ofthe joint seal 100 in deep joint substrates.

The joint seal 100 is constructed by providing a first body ofcompressible foam 120, providing a second body of compressible foam 128,providing a barrier 134, adhering the barrier 134 to the first body ofcompressible foam 120 at the first body bottom 122, and cutting thefirst body of compressible foam 120, the second body of compressiblefoam 128, and the barrier 134 to provide a common first end, a commonsecond end, a common first side and a common second side.

The method of construction may further include providing a third body ofcompressible foam 302, providing a second barrier 304, adhering thesecond barrier 304 to the second body of compressible foam 128 and tothe third body of compressible team 302, and cutting the third body ofcompressible foam 302 and second barrier 304 at the common first end, atthe common second end, at the common first slide and at the commonsecond side.

Once these components are joined into an integral unit, the joint seal100 may be cut to length and compressed and imposed between the firstsubstrate 102 and the second substrate 104. The integral unit providesadvantages after the prior art. Because the components are joined intothe joint seal 100 prior to installation, the dimensions of thecomponents are equal, providing a full edge on each surface, avoidingthe potential of exposed surfaces and permitting better joining at thebutt of each joint seal 100. Moreover, because the components are joinedprior to installation in the gap, a complete adhesion between eachcomponent and the adjacent component is obtained, rather than thepotential for air gaps between components and avoiding the potential forany offset in the actual gap, which could frustrate performance.Additionally, because the components are made integral beforeinstallation in the gap, the barrier is assured to be in the correctposition, such that destruction of the top body of compressible foam isdestroyed or rendered inoperable, the barrier maintains its function.

Additionally, the first body of compressible foam 120, the second bodyof compressible foam 128, and where present, the third body ofcompressible foam 302 may be provided with different compression ratios.Different compression ratios would facilitate the installation processand allow for compression ratios to be used that were previouslyunachievable in a single compression ratio system, such as where thefirst body of compressible foam 120 may have a lower compression ratio,while other bodies of compressible foam may have higher compressionratios, resulting in a joint seal 100 which is more watertight at thebottom, while more flexible on the top. As can be appreciated, thisstructure may be reversed for different properties.

Referring now to FIG. 10, the barrier 134 of the embodiment of FIG. 3may be provided with a barrier width 1002 which is greater than thefirst body width 124 and the second body width 132 to provide a firstwing 1006 and a second wing 1008. The second barrier 304 may have asecond barrier width 1004, greater than each of the second body width132 and the third body width 314. Each wing 1006, 1008 may include atits distant end 1010, 1012 an upper elongate appendage 1014, 1016 and,essentially co-planar and below, a lower elongate appendage 1018, 1020,formed, for example, by the lack of adhesive between two adjacent layersor bodies and by cutting a single layer along an edge 1022. Suchappendages may lap over or about a roofing system to provide aneffective seal, Referring now to FIG. 4, in an alternative embodiment400, the joint seal includes a first body of compressible foam 120, asecond body of compressible foam 128, and a barrier 134 adhered to boththe first body of compressible foam 120 and the second body ofcompressible foam 128, wherein the compressible bodies have equivalent,i.e. substantially the same, lengths and widths but the barrier extendsbeyond the edge of the first body of compressible foam 120 on at leastone side to provide a wing 402 can be turned up (or down) and adhered,at installation, to the substrate 102, 104. Additionally, a slow dryingadhesive may be applied to the wing 402 or to the second barrier 304before insertion. Traditional, faster drying adhesive, such as epoxy,are to be avoided as they can cure before insertion. Application of anadhesive to the wing 402 may provide a greater depth of seal and bondingarea.

This embodiment allows the barrier 134 to extend past the compressiblebody laminations and be used as wing 402 to be set into the concretesubstrate 102, as illustrated in FIG. 8. This is helpful for split faceconcrete or application where it is desirable to extend the propertiesof the barrier 134 past the edge of the joint substrate 102, 104, Thewing 402 provides a continuous bar against air penetration betweensections and with a joint substrate or other building material.

Further, as illustrated in FIG. 11, the wing 402 may include at itsdistant end 1002 an upper elongate appendage 1106 and essentiallyco-planar and below, a lower elongate appendage 1108, formed, forexample, by the lack of adhesive between two adjacent layers or bodiesand by cutting a single layer along its edge 1110. Such elongateappendages may lap over or about a roofing system to provide aneffective seal. Further, an elastomeric layer 1112 may be applied to thefirst body top 118 and bonded to facilitate a compression profile on thefirst body of compressible foam 120. The barrier 134 may be composed orone or more layers of a synthetic rubber roofing membrane, includingethylene propylene diene terpolymer (EPDM).

Referring now to FIG. 5, a further alternative embodiment 500 of thejoint seal 100 is illustrated. In the further alternative embodiment500, the barrier 134 protrudes beyond an end of the joint seal 100,beyond the first body first end 204, providing a tab 502. The barrier134 may have a resilient flexible barrier length 214 equivalent, i.e.substantially the same, to the first body length 202. The barrier 134may not be adhered to either the first body of compressible foam 120 orto the second body of compressible foam 128 and an opposing end, orpotentially at both ends of the joint seal 100, providing a separablegap 504. As a result, the tab 502 of one unit of the joint seal 100 maybe inserted into the end of an adjacent joint seal 100 in the separablegap 504. The length of the tab 502 and the distance of separable gap 504may be as much, or even more than, two inches. For example, a sixty (60)inch length of joint seal 500 may include a three (3) inch tab 502 and amatching length gap 504 where the lamination of the first body 120, thebarrier 134, and the second body 128 are bonded together, so thatunbonded tab 502 may be inserted and joined, such as with an adhesive onone or both of its top and bottom, to provide a continuous andoverlapping joint system. An adhesive seal may be used on each tab 502or in each separable gap 504 to tie adjacent joint seals 100 together soas to provide a continuous barrier along the length of the joint. Thisresolves a weakness, which may be substantial, of joint unions in jointconstruction and common cause of failure, which is usually accomplishedonly by bonding the butt ends of the joint seals 100 together.Continuous connections of the barrier 134 at joints provide an advantageover current splices, whether factory or field, which often are merelyadhesive or intumescent splices.

Referring to FIG. 12, the further alternative embodiment 500 of thejoint seal 100 may incorporate the wing 402, with an upper elongateappendage 1106 and essentially co-planar and below, a lower elongateappendage 1108 at its distant end 1102 of the embodiment of FIG. 11 withthe barrier 138 of FIG. 5. The barrier 138 may therefore be composed oftwo adjacent layers or bodies 1202 and 1204, which, while of uniformlength are unaligned at the ends 1206, 1208, resulting in the tab 502and the distance of separable gap 504.

Referring now to FIG. 6, in another further alternative embodiment ofthe joint seal 600, the barrier 134, which could be installed with asinusoidal structure to encourage deformation and rebounding, couldextend outside the edges of the first body 120 and the second body 128to provide a wing 602 to use an anchoring device and/or a continuationof the beneficial properties of the barrier 134. An example would beusing a water and fire resistant foam as the first body 120 with a thickdurable reinforced rubber or other similar water barrier 134 with aless-water resistant but more fire-resistant foam as the second body128. The rubber barrier 134 would be too thick to compress such that itwould work well as a moving joint seal but by using the integralsinusoidal pattern for the barrier 134, the first body 120 and thesecond body 128 can compress and work as a joint sealant. The rubberbarrier 134 would extend past the edge of the first body 120 and thesecond body 128 such that it could be set into a polymer nosing orconcrete or act as part of a split slab barrier. This reduces thelikelihood that water can move past the joint sealant 100 even if thetop seal generated by the first body 120 fails or the concrete spalls atthe edge of the joint. This is additionally helpful because the secondbody 128 can be selected for higher fire resistance and with lowerwaterproofing requirements. The wing 602 may include at its edge ananchor 603 of increased thickness.

Referring now to FIG. 13, the wing 602 may include at its distant end1302 an upper elongate appendage 1306 and essentially co-planar andbelow, a lower elongate appendage 1308, formed, for example, by the lackof adhesive between two adjacent layers or bodies and by cutting asingle layer along its edge 1310. Such appendages 1306, 1308 may lapover or about a roofing system to provide an effective seal. Further, anelastomeric layer 1312 may be applied to the first body top 118. Theelastomer layer 1312 may terminate at the first body first side 206 andthe first body second side 207, may extend slightly past die first bodyfirst side 206 and the first body second side 207 to provide an overlapof the top edge or the adjacent substrate, or may continue along at thefirst body first side 206 and the first body second side 207 to providea silicone-to-silicone bonding surface with the substrate, which mayprovide a positive seal in circumstances when the substrate is rough oruneven. The barrier 134 may be composed or one or more layers of asynthetic rubber roofing membrane, including ethylene propylene dieneterpolymer (EPDM), bonded to the first body top 118.

Referring now to FIG. 7, in another further alternative embodiment 700,the barrier 134 may be of a narrower width than the first body 120 andthe second body 128. Thus, the barrier 134 may terminate short of theedge of the first body 120 and the second body 128. This variationallows for the benefit of the different foams for the first body 120 andthe second body 128 and also allows for the barrier 134 to accept lesscompression while still providing its intended properties.

In connection with each embodiment, cutting the first body 120 and thesecond body 128 into interlocking (male/female) sections using a radiusof at least 0.1875 inches permits a thicker barrier 134 to be usedwithout bowing or deformation of the foam, a benefit previouslyavailable only when a thin barrier 134 might be used. In the prior art,use of a random accordion style would cause the barrier 134 to fatigueafter cycling.

An example is a joint seal using two different fire-rated foams as thefirst body 120 and the second body 128 adhesively bonded together with abarrier 134 of copper foil to block EMF radiation. A barrier 134 ofcopper would not be as flexible as the foam of the first body 120 andthe second body 128 and would benefit from the sides of the first body120 and the second body 128 compressing before the barrier 134 of copperwould need to compress or flex. The resultant joint sealant 700 wouldserve to provide a fire-resistant material required in sound booths,studios, and concert halls, and offer the benefit of the barrier 134 ofcopper serving as flexible (compressible) EMF blocking device.

The joint seal 100 may provide an elegant transition in lieu of verticaland horizontal expansion joint, eliminating the need for two trades toinstall a connection for a vertical expansion joint. The typicalarrangement of roofers providing roof joints and roofing whilewaterproofers provide the expansion joints is therefore eliminated. Itis well known in the art that joints tend to leak or fail at changes indirection or plane and where dissimilar joint types or materials areintended to join. The joint seal 100 of the present disclosure addressesthis shortcoming by simplifying the connection between the two planes—byusing the same material for the roof expansion joint and the verticalwall expansion joint. Multiple joint seals 100 can be adhesively, ormechanically and adhesively, connected as they are made of similarmaterials and have similar thermal and expansion properties. The jointseal 100 may span the transition points, anywhere from an angle greaterthan zero to an angle less than 180 degrees.

Referring to FIGS. 14A, 14B, 14C 14D, 14E and 14F, the joint seal 100provides the advantageous characteristic of being usable for bothhorizontal joints and vertical joints by use of a transition. Thesetransitions may be formed of a single foam section of each layer, or bythe use of multiple sections. Referring to FIG. 14A, a factorytransition 1402 from a horizontal to vertical joint may be provided suchthat the first body of compressible foam 120 and the second body ofcompressible foam 128 are each formed to include a right angle turn,such that the two layers 1404, 1406 are adjacent throughout thetransition, separated by a continuous barrier 1405. Referring to FIG.14B, a transition 1408 provides a section 1410 of one of the first bodyof compressible foam and the second body of compressible foam joined orattached to another section 1412 in right angle abutment and theassociated section 1414 of the second body of compressible foam and thefirst body of compressible foam is joined or attached to the othersection 1416 in a mitered cut. In this embodiment, and in those of FIGS.14B-14F, the barrier 1413 may be continuous, may be two abuttingsections, or may be overlapping sections. Alternatively, the abutmenttype may be reversed between the first body of compressible foam 120 andthe second body of compressible foam 128 or one pair of abutted orjoined sections may be replaced with a continuous, right-angle bodyillustrated in FIG. 14A. In a further alternative, both the first bodyof compressible foam 120 and the second body of compressible foam 128may be joined with a miter cut. Referring to FIG. 14C, the transition1417 from a horizontal to vertical joint is illustrated wherein thefirst body of compressible foam 120 and the second body of compressiblefoam 128 of one section 1418 is joined or attached to another section1420 in a mitered cut. Alternatively, the first body of compressiblefoam 120 and the second body of compressible foam 128 may be terminatedto provide an offset to prevent separation in a field perpendicular tothe runs of the bodies. Referring to FIG. 14D, a transition 1421 from ahorizontal to vertical joint is illustrated wherein a section 1422 ofone of the first body of compressible foam 120 and the second body ofcompressible foam 128 is joined or attached to another section 1424 inright angle abutment and the associated section 1426 of the second bodyof compressible foam 128 and the first body of compressible foam 120 isjoined or attached to the other section 1428 in a offset right angleabutment, such that the ends of the first body of compressible foam 120and the second body of compressible foam 128 are not co terminus.Similarly, when an offset ending is used for the joint seal 100, thetransition may be constructed to be immediately adjacent the end, andthe abutting end of a first body of compressible foam 120 and the secondbody of compressible foam 128 may be provided with a mitered or taperedcut ending, promoting different rates of compression within thetransition when constructed. Referring to FIG. 14E, such a transition1429 is illustrated wherein a section 1434 of one of the first body ofcompressible foam 120 and the second body of compressible foam 128,which includes a right angle extension occurring beyond the first end ofone body and terminating in a mitered cut, is joined or attached toanother section 1430 in right angle abutment, but wherein the one of thefirst body of compressible foam 120 and the second body of compressiblefoam 128 terminates in a mitered cut. Further, the transitionsillustrated in FIGS. 14A, 14B, 14C and 14D may likewise include one ofthe first body of compressible foam 120 and the second body ofcompressible foam 128 terminating beyond the other in a mitered cut.Referring to FIG. 14F, a transition 1437 is illustrated wherein at leastone of the first body of compressible foam 120 and the second body ofcompressible foam 128 terminates in a mitered cut, providing sections1438 and 1440. Further, the bond between the first body of compressiblefoam, the barrier and/or the second body of compressible foam may betemporary, allowing a more independent operation alter installation.

The transition may further include a barrier 134 and provide the tab 502and the associated offset for interlacing barriers and tie-in functionto the substrate or other building material.

Referring to FIG. 15, the joint seal 100 may further be integrated withother accessories known in the art. For example, a walking pad 1502 maybe affixed to the first body top 118, or to the elastomeric layer 1312or to the barrier 134, particularly for roof areas requiring foot orother traffic access. The elastomeric layer 1312 or to the barrier 134can further include a layer of a fire barrier coating such as FireOut™Fire Barrier Coating by GAF, applied above or below the roof joint.Alternatively, such a walking pad 1502 could be unbonded on extendedwalking areas, functioning essentially as a protective cover plate, overthe joint seal 100. The walking pad 1502, cover plate or aestheticexpansion joint cover need not be of the same materials as the jointseal 100 as they do not perform a sealing function but rather anotheradditional function such as, but not limited to slip resistance. Thejoint seal 100 may further include a drain 1504 through the first bodyof compressible foam 120, which may extend into the bottom of the secondbarrier 304 when present, to drain any moisture or water if it everaccumulated inside the joint seal 100. The drain 1504 may be connectedto a tube or pipe 1506 to drain or direct the water to an exterioroutlet 1508 which may drain to a drainage system, such as guttering,providing an important feature in creating a fail-safe roof jointsystem. Alternatively, the drain 1504 may communicate with the secondbody of compressible foam 128, which second body of compressible foam128 may shed downward the associated water.

Referring to FIG. 16, the structure of the joint seal 100 may becontoured to deflect water. A crown 1602 or crest may be positioned inthe middle of the joint seal 100 such that water does not accumulate onthe joint seal 100 but rather runs off the joint seal 100. The wings1006, 1008 may further be used as a flashing to divert the water awayfrom the expansion joint. The crown 1602, which may be concave, convexor have a shaped profile, may extend from the end of the joint seal 100such that it extends from the first body first side 206 side of firstbody of compressible foam 120 to its second side 206, providing acontinuous layer providing functional benefit, such as, but not limitedto, water resistance. Thus, the second barrier 304 can provide a unifiedroofing system while the barrier 134 can serve as a flashing or waterdiversion membrane. In this instance the barrier 134 may be much thickeror longer than the second barrier 304 or it may be the same dimensions.Each of the bodies of compressible foam may include this crownstructure, provided the adjacent surface of the adjacent body has asimilar crown structure, such that the bodies nest about the curvesmembrane. Similarly, the material can be supplied in a concave or valleydesign to act as a trough or a drain to divert water along the expansionjoint to a roof drain (even one internal to the roof joint) or otherexit point. The trough or valley can be tapered to the drainage point bygradually recessing the expansion joint assembly or by reducing theamount of foam about the barrier 134 or by reducing the thickness 123 ofthe first body 120 such that it allows the water to flow in the intendeddirection. It is anticipated that other functional systems may beintegrated into the expansion joint or the functional membrane such as avent, conduit connection or other connection or function for energyefficiency systems such as solar panels. A unified, continuousmulti-functional joint seal is thus provided across multiple planeswithout the need for further components, such as mechanical transitionsor covers.

Referring to FIG. 17, the joint seal 100 may have a first body ofcompressible foam 120 and a second body of compressible foam 128 whichare not co-terminus. The resulting offset 1702 provides an area withouta coating to receive an extended functional layer from the joiningsection. The offset may prove particularly beneficial in areascontemplated to have standing water. Such a structure may beparticularly advantageous when field splices are contemplated.

In each embodiment, the composition of the present disclosure, the jointseal 100 reduces the need for additional insulation, as the materialsupplied can yield an R-value of 3.2R per inch of depth or greater,although additional insulation may be used to reduce the depth of sealfoam required or to gain a higher insulation value. Beneficially, thejoint seal 100 of the present disclosure may add LEED points to abuilding due to the improvements in reducing air loss and addinginsulation value. This may be particularly important where the jointseal 100 is used in connection with roof joints, as hot air may rise andseek to escape through such joints. Traditional expansion and roofjoints may be watertight but are not necessary known to require or betested for air tightness, especially to meet standards such as the ABAArequirements in the form of an assembly that has an air leakage not toexceed 0.04 cubic feet per minute per square foot under a pressuredifferential of 1.57 pounds per square foot (0.04 cfm/ft ²@1.57 psf)(0.2 liters per square meter per second under a pressure differential of75 Pa (0.2 L/(s·m²)@75 Pa)) when tested in accordance with ASTME2357-11. Other moisture and airtightness tests include, withoutlimitation, ASTM E-283, E-330, E-331, E-547, TAS 202/203 and ASTME2178-11. Historically, most building materials, foam joint sealants androot joints have not met the requirements of these tests, in particular,when required to transition between dissimilar systems to provide acomplete system or assembly. For the highest air barrier standards,E-2357-11 and ASTM E2178-11 only specialized wall covering systemsspecifically for airtightness have done so and only to the extent thatthey are a field applied cover or coating other systems.

The use of the method would have other uses obvious to those familiarwith the trade to provide a flexible or compressible medium or joint formaterials that are fragile or too rigid to allow for movement over anexpansion joint. A variation to this method for materials that are thickor would require a higher degree of movement would be to cut the foam insuch a pattern to allow for the barrier to bend or flex in a wave-typepattern. For smaller, thinner barriers the foam is typically resilientand compressible enough to allow for the variation in the barrier. Forthicker or more rigid barriers it has been found better to cut the foaminto a wavy or zig-zag pattern such that the two sections of foam nestinto each other (or male-female sections). Thereafter the barrier isadhered to both sections such that when the resulting joint material iscompressed the barrier folds with the foam and allows for greater jointmovement than if affixed as a thick straight barrier. Another use ofthis method is to solve the problem of foam joint sealant densities andseparating foams with competing properties. Such is the use of one bodythat is designed to be hydrophobic (some may be slightly to keep out adriving rain other more so for standing water) in its function or notall and the second body is designed to be hydrophilic. In this case thewaterproof (and maybe radon proof) harder separates the hydrophilic bodythat will absorb water or moisture increasing its internal compressiveforce to stop water penetration but does so in a variable method so somewater can penetrate before it has expanded enough to seal the joint.This is undesirable and can lead to mold in confined spaces. The firstbody 120 can be designed to work as intended and offer a dry exposedsurface area. In operation, the first body of the compressible foam 120or the second body of the compressible foam 128 could be at leastpartially impregnated with a liquid hydrophobic sealing composition,i.e. in a liquid medium, or with a liquid hydrophilic sealingcomposition.

Watertight unions can be created by offset cuts, angles etc, or by usingthe membrane extensions on the ends to join the lengths together by heatseaming/welding, adhesive bonding or a mechanical connection. Factoryversions can be made having continuous internal membranes in longerlengths to reduce the number of required splices or unions.

Preferably and unlike the prior art, the present disclosure permits ajoint movement of +/−50% movement, i.e. 100% total, of Class I, II, IIIMovement per ASTM E-1399 while serving in joints up to 12″ wide as aself-supporting horizontal system. While ASTM E-1399 is an acceptedindustry standard however, the total cycles required my not beconsistent with real world experience. Beneficially, the barrier 134reduces the potential for compression set and cycling fatigue of thefirst body 120 and the second body 128, and therefor of the joint seal100, as test samples passed 10,000 cycles or more with no sign offailure. This may be greater than 10 years of thermal cycling and 20times more than required by ASTM 1399-97 (2000). Moreover, the presentdisclosure may be used for seismic movement, in addition to highmovement installations.

Additionally, the joint seal 100 has substantial benefits over the priorart. The joint seal 100 can be used underneath a traditional bellowstype roof expansion joint to provide redundancy and further sealing. Thefirst body 120 and the second body 128 do not need to have a fire ratinglisting, such as with Underwriters Laboratories, but rather can be fireresistant to pass or have results acceptable to provide the intendedbuilding code function. Foams sealants are known which pass applicablestandards such as UL94, ASTM E-84, ASTM E-119, EN1399, AS1504.3, BS476,DIN 4102-1, DIN 4102-4 F120, DIN 18542, BGI through their intendedmovement range and tested at the maximum dimension. Beneficially, if thejoint seal 100 is used in an area requiring seismic movementrequirements, the joint seal 100 meets all of the cycling requirementsof UL 2079 and ASTM E-1366 for slow and rapid joint cycling.

The disclosure provides a multi-layer joint system wherein bodies offoam 120, 128, layered co-planar to the adjacent surface, areinterspersed with a barrier 134. The foam bodies 120, 128 may beuncompressed or partially compressed at the time of joint seal formationand may be composed of an open cell, closed cell or hybrid foamimpregnated or infused with a pressure-sensitive adhesive, which couldbe acrylic, styrene butadiene rubber (SBR), rubber, wax, asphalt orothers apparent to those experienced in the trade, or an unprocessed(fully or partially) open or closed, or hybrid, cell foam. Any of thefoam bodies 120, 128 or the barrier 134 may be selected from aself-sealing polymer impregnated design or an internal foam sealant sothat, even if compromised, the seal provides a complete seal. A foambody 120, 128 may be impregnated with a fire retardant, if at all, ormay be composed of a fire-retardant material, if desired. The barrier134 may have a tensile strength greater than the adjacent foam bodies120, 128 (which may be much greater). The joint seal may have anelastomer 138, such as silicone, at its top and/or bottom, and may eveninclude an elastomer layer within the barrier 134.

The foregoing disclosure and description is illustrative and explanatorythereof. Various changes in the details of the illustrated constructionmay be made within the scope of the appended claims without departingfrom the spirit of the invention. The present invention should only belimited by the following claims and their legal equivalents.

What is claimed is:
 1. A joint seal, comprising, a first both ofcompressible foam, the first body of compressible foam having a firstbody bottom and a first body width; a second body of compressible foam,the second body of compressible foam having a second body top and asecond body width; a barrier, the barrier adhered to the first body ofcompressible foam at the first body bottom, the barrier adhered to thesecond body of compressible foam at the second body top, the barrierhaving a barrier width greater than each of the first body width and thesecond body width, the barrier including a layer from at least one of aheat barrier, an infrared barrier, a high tensile barrier, a waterbarrier, air barrier and a vapor barrier.
 2. The joint seal of claim 1further comprising, the barrier having a first wing extending beyond afirst body first side and a second wing extending beyond a first bodysecond side; the first wing haying a first wing end, the barrierterminating at the first wing end in a first wing upper elongateappendage and a first wing lower elongate appendage; the second winghaving a second wing end, the barrier terminating at the second wing endin a second wing upper elongate appendage and a second wing lowerelongate appendage.
 3. The joint seal of claim 1, wherein the first bodyof compressible foam has a first body fire rating and the second body ofcompressible foam has a second body fire rating, the first body firerating and the second body fire rating being unequal.
 4. The joint sealof claim 1 further comprising: a third body of compressible foam, thethird body of compressible foam having a third body top and a third bodywidth; a second barrier, the second barrier adhered to the second bodyof compressible foam at a second body bottom, the second barrier adheredto the third body of compressible foam at the third body top, the secondbarrier having a second barrier width greater than each of the secondbody width and the third body width, the second barrier including alayer from at least one of a heat barrier, an infrared barrier, a hightensile harrier, a water barrier, air barrier and a vapor barrier,


5. The joint seal of claim 3 further comprising: a first body first endand a barrier first end being co-planar, and the first body first endand a second barrier first end being co-planar.
 6. The joint seal ofclaim 1 further comprising: a first body length, a barrier length, and asecond body length being substantially the same.
 7. The joint seal ofclaim 1 further comprising: the first body width and the second bodywidth being substantially the same.
 8. The joint seal of claim 1 furthercomprising: a first body first end and a barrier first end beingco-planar.
 9. The joint seal of claim 1 further comprising: the firstbody of compressible foam being impregnated with a fire-retardantcomposition delivered in a liquid medium.
 11. The joint seal of claim 1further comprising: the first body of compressible foam being composedof a fire-retardant material.
 12. The joint seal of claim 1 furthercomprising: the second body of compressible foam being impregnated witha fire-retardant composition delivered in a liquid medium.
 13. The jointseal of claim 1 further comprising: the second body of compressible foambeing composed of a fire-retardant material.
 14. The joint seal of claim1 further comprising: a moisture sensitive radio frequencyidentification device in contact with the first body of compressiblefoam.
 15. The joint seal of claim 1 further comprising: a heat sensitiveradio frequency identification device.
 16. The joint seal of claim 1wherein the barrier is electrically conductive and further comprising: aradio frequency identification device in electrical connection with thebarrier.
 17. The joint seal of claim 1 wherein the barrier is heatconductive and further comprising: a heat sensitive radio frequencyidentification device in electrical connection with the barrier.
 18. Thejoint seal of claim 1, further comprising: a resilient flexible surfacebarrier, the resilient flexible surface barrier adhered to the firstbody of compressible foam at a first body top of the first body ofcompressible foam, the resilient flexible surface barrier having aresilient flexible surface barrier width greater than the first bodywidth, the resilient flexible surface barrier including a layer from atleast one of a heat barrier, an infrared barrier, a high tensilebarrier, a water barrier, air barrier and a vapor barrier.
 19. The jointseal of claim 18, wherein at least one of the barrier and the resilientflexible surface barrier has a first wing extending beyond a first bodyfirst side and a second wing extending beyond a first body second side;the first wing having a first wing end, the barrier terminating at thefirst wing end in a first wing upper elongate appendage and a first winglower elongate appendage; the second wing having a second wing end, thebarrier terminating at the second wing end in a second wing upperelongate appendage and a second wing lower elongate appendage.
 20. Thejoint seal of claim 1, wherein a first body top of the first body ofcompressible foam further includes a crown at a middle of the first bodytop to increase a thickness of the first body of compressible foam.